Apparatus for producing fibrous glass



May 2, 1944. SLAY'TER 7 2,343,182

APPARATUS -FOR PRODUCING FIBROUS GLASS Original Filed Aug. 4, 1938 5 Sheets-Sheet l IVNVENTOR. Games 'lcz yl'ef;

ATTORNEY May 2, 1944. G. SLAYTER 2,348,182

APPARATUS FOR PRODUCING FIBROUS GLASS Original Filed Aug. 4, 1938 s Sheets-Shet 2 v INVEN TOR. Games Jlcg/ter,

ATTORNEY May 2, 1944. G. SLAYTER APPARATUS FOR PRObUCING FIBROUS GLASS Original Filed Aug. 4, 1938 3 Sheets-Sheet 3 defer, Ar r vsy INVENTOR. Games 6' Patented May 2,

UNITED STATES ATENT OFFICE I 2,348,182 APPARATUS FOB- PBODUCING FIBBDUS GLASS (Binaries Slayter, Newark, Ohio, assignor, by mesne assigmmnts, to Owens-Corning Fiberglas poration, Toledo, Ohio, a corporation of Dela- .ware

Cor-

Originai application August 4, 1938, Serial No. 223,104. Divided and this application August 16, 1940, Serial No. 352,912

lClaims.

The present invention relates to improved apparatu's for producing corrugated, wavy or crimped fibrous glass and tangled or felted mats of crimped fibrous glass.

The present invention also relates in part to an apparatus for attenuating a multiplicity of glass fibers by mechanical means and-simultaneously producing a twisted yarn thereof.

This application is a division of my copending application, Serial Number 223,104, filed August 4, 1938, now Patent Number 2,230,272.

Heretofore attempts have been made to produce crimped fibrous glass, but the methods of production were limited to those used ordinarily for mechanically drawing fibrous glass and the glass was crimped as an intermediate step while the glass was in a formative stage. Synchronization between the attenuating means, the crimping rolls and the temperature means had to be made. Y I

The fibrous products made by this mechanical drawing process consisted of layers of fibers lying on top of one another more or less parallel with the major surface of the mat. The corrugated fibers were corrugated in butone plane so that the'fiber would lie fiat and pile up in that form. There was no entanglement or felting of the glass fibers, nor, were there fibers running in directions transverse to the stratifications or layers.

An object of ,the invention is to produce a fibrous glass product consisting of crimped fibers wherein the glass fibers may be entangled and felted to produce a product having vastly increased resilience in all directions, compressibility, lightness in weight and mass integrity.

Owing to the crimped nature of the fiber, an entanglement or felting is diflicult to achieve, for it will be noted that the fibers possess substantial dimensions in more than one direction. It is thus dimcult'for a crimped fiber to penetrate through small interstices present in the fibrous mass.

Another object of the present invention is to produce crimped glass fibers at extremely high 45 speeds comparable with and even superior to those achieved by the steam blown process illustrated and described in the Slayter and Thomas Patent 2,133,236, dated October'll, 1938.

Still another object of the invention is to produce crimped glass fibers by my improved apparatus and simultaneously provide means for lubricating the fibers as they are being attenuated.

Still another object of the invention is to pro- 55 vide apparatus for producingcrimped fibers wherein conditions may be controlled for producing various fiber diameters, according to the nature of the product desired. It is also an ob- 5 ject to permit adjustment of conditions whereby a varying degree of crim'p may be imparted to the fiber and also, if desired, all crimp may be dissipated before final set of the glass fibers.

A further object is to produce fibrous glass ,10 which lies in one or more planes; that is, the

fiber may be corrugated in but one plane or the the fiber may be twisted in addition to lie in a multiplicity of planes and extend in substantially all directions.

An ancillary object of the invention is to attenuate fibrous glass mechanically bymeans of two coacting traction surfaces which do not pinch, squeeze orlcrush the fibers therebetween as they are attenuating the same.

Still another ancillary object of the present invention is to provide crimping rolls having a gear-shaped formation, which are mechanically independent from one another and yet move in synchronism at extremely high speeds. When operating at high speeds the fibers will free themselves from each of the rolls tangentially without wrapping themselves about one or the other.

Another object is to provide a novel syn- 0 chronous drive for the rolls which is not limited to speeds attainable by a mechanical linkage or a connection.

Another object of the present invention is to provide, if desired, means for cooling the glass streams at or shortly after they have left the orifice outlet openings of the supply body. The

the apparatus shown in Fig. 1, the section being taken along the line II--II of Fig. 1;

Fig. 3 is an elevational view of a modified embodiment of the present invention adapted to produce crimped fibrous glass;

Fig. 4 is a cross-sectional view of the apparatus stream of glass being attenuated and crimped by means of coacting gear-shaped members;

Fig. 6 is a diagrammatic cross-sectional view which illustrates a modified embodiment of the present invention, showing the crimped fibrous glass being thrown out under conditions to cause the glassfibers to entangle with one another and treated with a coating material prior to their deposition in bat form;

Fig. 7 is an elevational cross-sectional view of another modified embodiment of the present invention, showing means for lubricating the fibrous glass prior to complete attenuation;

Fig. 8 is a diagrammatic elevational view of apparatus for attenuating fibrous glass and simultaneously forming the same into a twisted yarn; and a Fig. 9 is a diagrammatic plan view of a modified embodiment of the present invention.

The present invention contemplates the simultaneous mechanical attenuation and crimping of a glass stream into wavy fibrous form by means of suitable apparatus such as coacting. gearshaped members. The individual teeth of the respective gears or crimping rolls are made to run interjacent althoughspaced apart fromone another. Clearance is thus provided to permit the glass streams-or fibers to pass therethrough without being crushed or squeezed. Sumcient traction may be imparted, however, to the fiber as itpasses in zigzag formation, that attenuation may be effected without excessive wear or friction upon the coacting crimping rolls.

After being attenuated, the crimped glass fibers may be fabricated into suitable products as desired. For example, they'may' be deposited directly upon a belt and built up into mat formation. To facilitate an interfelting, I have discovered that twisting and/or entanglement of the fibers prior to deposition is beneficial, and for this purpose, a temperatur control whereby the glass emerging from the crimping rolls is still in a partially plastic or formative stage, is desirable. When the glass is still in' a partially plastic stage as it emerges from the rolls, and the fibers are permitted by means of turbulence, or extremely high speeds of formation, to twist and tangle with one another, the fibers after depositing upon the belt, or prior thereto, may be chilled and set in their twisted or tangled formation. In this connection, the crimped fibers may be deposited upon a conveyor in partially plastic condition, or rendered plastic thereafter, and then work, compressed or compacted into felted'form of predetermined density and dimensions.

Referring now more particularly to Figs. 1 and 2, reference character In designates a glass feeder appurtenant to a glass tank or other supply body. The design of this feeder may be as desired, although satisfactory results have been achieved by means of a feeder illustrated and described in the Thomas and Fletcher Patent No. 2,165,318. Located below the feeder iii-may be, if desired, a blower orother cooling apparatus ll suitable to facilitate attenuation in accordance with the British Patent No. 482,085.- The blower ll, however, may be or may not be used according to the type of stream forming apparatus which is to be used.

.Spaced below the feeder are coacting crimping rotorsor rolls l3 l0 and the blower II, and I4 respectively, having a gear-like cross-section and provided around the periphery thereof with a series of radially extending projections 15 which may be in the form of teeth, as shown, or bails each having its ends disposed towards the axes of rotation of the rolls. Each of the crimping rolls l3 and I4 is keyed to shafts l6 and I1 respectively, which inturn are mounted upon sup; orts I8 and i9 respectively. The support 18 is pivoted at its lower end upon a cantilever beam 20 by means of a pin 20 The support I9 is also fixed upon the cantilever beam 20 at its lower end, and is held in fixed position at the upper end by cantilever beam 2|. The beams 20 and 2! may be bolted to a slide member 22, adapted 'to slide vertically upon a base or framework 23.

30, and at synchronous speeds whereby the respective teeth l5 of the crimping rolls intermesh without engaging or touching each other.

A suitable interconnecting mechanism may consist of a gear box 3|, a pulley 32, belt 33, and pulley 34, leading to gear trains communicating with the respective crimping rolls. The gear trains are all driven synchronously from the pulley 34 which is fixed to orintegral with.a gear 35.

The gear 35 drives the crimping roll I 4 through intermediate gear 31 and gear 38 which is keyed to the shaft l1 of the'crimping roll l4. Intermediate gear 31 may be mounted upon the support l9.

The gear 35 drives the crimping roll I3 through gear 40, intermediate gear 4|, and gear 42 which is keyed to the shaft 16 of the crimping roll 13. Intermediate gear 4| is mounted upon the pivoted support l8.

Mechanism for holding the crimping roll l3 at any predetermined distance from the crimping roll l4, includes a set screw 45 located on the inner side of the support l9, and adapted to abut the support IS. The set screw 45 may be adjusted to permit the crimping rolls to come together to any desired degree.

Mounted upon the support I8 is a plate 50 having upstandingflanges 5| between which is a pivoted finger 52, fulcrumed upon pivot 53. The finger 52 at one end is provided with a roughened thumb plate 54 which may be pressed to throw the opposite end of the finger out of alignment with the support l9 and thus enable the crimping rolls to be moved together in operative position. When it is desired to move the crimping roll l3 out of operative position, a handle 55 integral with the support [8 may be pulled out'and the finger 52 turned to be in alignment with and abut the support IS. The finger 52 thus holds the crimping roll 13 out of operative position with the crimping roll l4.

Spaced below the crimping rolls l3 and i4 is a bat forming unit consistingof a traveling support or conveyor 60 upon which the crimped fibers descend and deposit themselves in a mat formation. A hood fil may be provided to direct the fibers. upon the conveyor 60. If desired, the fibers may be compressed by means of a caterpillar belt 62 mounted over the mat and conveyor 60 and, if desired, into the mouth of the hood.

In operation of this device the two crimping 1-0115 are driven simultaneously and in complete synchronism with one another from the common driving gear 35. The crimping roll l3 may be pulled into andout'of engagement with the crimping roll l4 during operation of the gearsv and without interrupting their mutual synchronism.- This, it will be observed, is done by X causing the crimping roll l3 and cooperating drivtermeshing of the gear trains. A

The apparatus illustrated and described in Figs. 1 and 2 is ideally suitable for producing crimped fibers of what might be considered a relatively coarse type,lthat, is having a diameter in the ordinary ranges of about .001 to .1 inch, this type of fiber being particularly adaptable for air filtration media although obviously suitable also for heat and sound insulation, etc. While high speeds of production may be used, the mechanical difliculties encountered in the use of gear trains,-generally limit the speed of attenuation of the fibrous glass be ow that desirable for highest speed and finest fiber formation. For this purpose, I have designed a high speed apparatus controlled solely by electrical means, references being made in Figs. 3 and 4.

In Figs. 3 and 4, reference character 85 designates a fiber glass feeder adapted to provide a multiplicityof glass streams 66.. Spaced below the feeder 85 are coactin crimping rolls 8'! and 88 respectively, each provided with a series of crimping teeth 89 around the periphery thereof adapted to intermesh with,-.one another. The crimping roll 81 is keyed to a motorshaft 10 of a niotor l l. The crimping roll 68 is keyed to a similar motor shaft 12 of a motor 13. Motor 13 is bolted to a vertically adjustable base plate I5 having an aperture 16 therein for the passage of the fibers I8 emerging from the crimping rolls.

Motor II is mounted upon a horizontal slide 19, sliding in the slide channel 80 which is bolted to the baseplate 15. Screw 82 fixed at one'end to the slide 19 by means of a lug 83, may coact with an internally threaded member or nut 84, mounted upon the base plate by means of a lug 85. A crank 89 is fixed to the free end of the screw 82, and may be rotated either way in order to move the slide 19 and crimping roll 81 to any desired distance from the crimping roll 88. Vertical movement may be imparted to the base plate 15 by means of vertical screw posts 88 upon which the base plate is mounted. The vertical screw posts 88 are all interconnected with one, another by means of a chain 89 and sprockets 88" to operate synchronously. The screw posts may be driven by any suitable means such as bevel gears 90 and 9| actuated by drive shaft 92 (see Fig. 3). Supplementary guide posts 95, passing through the base plate 15, may be provided to contribute housing so that it passes out through the opening I03 where it is directedupon the glass streams 68. The drafts or blasts of airemerging from the openings l03 may induce more air over the top of the housing against the glass as it emerges from the feeder 85.

An oil spray I04 may be provided in either one or both of the housings I00 and l 0 I to incorporate an oil-fog or vapor into'theair stream passing through the ppenings I03. Theglass streams 86 andresulting fibers may thus be lubricated by oil or other suitable lubricant prior to physical contact either with other fibers or by the crimping rolls themselves. The motors H and 13 may be of any suitable design, although preferably they are of a synchronous motor type, such as conventional synchronous motors or reluctance motors, and they may be synchro-tied with one another in order to insure absolute synchronism of the crimping rolls during operation irrespective of the speed of attenuation. When using ordinary synchronous motors, or synchronous reluctance motors, they may each be electrically connected to a common source of high frequency current, such as a motorgenerator, electron tubes, spark gaps or the like,

an inch to about a thousandth or an inch is suit able for ordinary purposes, such as heat insulating bats, blankets, or the like. Ordinarily,

, crimped fibers having several times the diameter of straight fibers may be used without increasing physical irritation or affecting deleteriously the feel or flexibility of the product. For this reason, coarser crimped fibers of say .001 inch may more successfully be used for a great many purposes than straight fibers.

In addition, varying types of products, may be produced by adjusting conditions, principally the temperatures at which the fibers pass through the crimping rolls. If the glass has been chilled below what appears to be the softening point prior to the delivery in the gears, the fibers pass through in the usual zigzag formation but straighten out again as they emerge from the rolls.

Such a formation is illustrated diagrammatically in Fig. 8 where it will be noted that a fiber H0 is passing downwardly between the crimping rolls Ill and H2 respectively, and then emerges again as a straight fiber I I3. Such fibers may be-fabricated as desired as, for example, they may be deposited upon a belt and accumulated in mat formation thereon. If desired, they may be fabricated directly into a yarn by wrapping them upon a rotating drum, as illustrated in British Patent No. 482,085; If desired, a multiplicity of such fibers H3 emerging from rolls Ill and I I2 may be simultaneously twisted and packaged by an internal winding into a rotatingbucket H4.

' If the temperature conditions of the glass streams as theypass through the crimping rolls is sufliciently high so that the glass after emerging from the rolls is above what appears to'be the softening point, or at least is still in a formative stage, the fibers are free to twistand bend so that ultimate fibers having portions of their length in substantially all directions maybe produced. Such a process is illustrated diagramsubstantially -identical speeds.

, ing in all directions are partially tangled or prefelted. another condition difllcult to achieve by I merely laying fibers upon a surface since the fibers having crimps lying in all planes are difilcult to penetrate into the interstices between the fibers in the mat.

As shown in Fig. 6 the crimped fibers l8 tangle and twist in the gaseous atmosphere below the crimping device and then deposit themselves freely upon a continuously moving surface or conveyor H6 toiorm a highly resilient mat III. A hood IIB may be used to confine the deposition to a predetermined surface upon the conveyor l 1.6. If desired, rolls H9 may be provided to increase the interfelting of the fibers. These rolls may be driven in the direction of the arrows, or may be what is known as idler rolls.

Fig. 6 also illustrates a lubricant or binder applicator I20 adapted to spray a suitable treating material I2I upon the fibers as they descend and deposit themselves upon the belt H6. The binder may be of any suitable composition such as natural or artificial resins, including both the thermoplastic and thermosetting type, glue,

asphalt, casein, sodium silicate, starch, plaster of Paris, borax, oil, fatty acids, soluble and/or insoluble soap, rubber, latex, linseed oil, agar agar, oils, fats, clay, bentonite, pitches, gums, or combinations thereof according to the properties desired.

In Fig. -7 a modified embodiment of the present invention is shown comprising crimping rolls I23 and I24 intermeshing with one another, housings I25 and I26 over the crimping rolls respectively, guide skirts I21 and I28 arranged under the crimping rolls respectively to facilitate emission of'the crimped fibers, and a lubricant spray gun I29 having its nozzle located directly over the point of intermeshing of the crimping rolls. Such an arrangement of the spray gun I29 permits a lubricant to be applied to the glass fibers prior to and as they enter the crimping rolls to insure minimum friction or scratching of the fibers, and prevent premature wearing of the rolls.

In Fig. 9 I have diagrammatically illustrated another arrangement whereby individual motors other than electrically synchro-tied, motors may be used. In Fig. 9' reference characters I30 and I3I designate intermeshing crimping rolls keyed to motor shafts I32 and I33, respectively, of motors I34 and I35, respectively. On each motor shaft I32 and I33 is keyed a synchronizing gear I36 and I31, respectively, intermeshing with one another. 'Ijhe synchronizing gears.l36 and I31 cause the crimping rolls I30 and I3I to continually intermesh with one another withouttouching or engaging the respective teeth. With such an arrangement it is possible to use ordinary high speed induction motors or any other type of electrical motor as desired.

It will be noted that the load carried by the synchronizing gears I36 and I3I' is relatively light since the two motors inherently operate at If -desired, one of these motors may be eliminated and only one motor used to provide power to both crimping rolls via intermeshing gears I36 and I31.

resorted to withinthe spi t and scope or the present invention as -defined in the appended claims.

Iclaim:'- 1. Apparatus for producing" crimped fibrous glass which comprises meansv for flowing a stream .of molten 'glass,""a' pair .of intermeshing geareach of said 'motors' being supplied with a common source of electrical energy, and meansior moving said members selectively into and out of intermeshing relation.

2. Apparatus for producing crimped fibrous glass which comprises means for flowing a stream of molten glass, intermeshing driven gear-shaped members having radially extending teeth around Various modifications and variations may be 7 the'per'iphery thereof between which said glass stream passes andby which it is simultaneously attenuated and crimped, a housing individual to and "around each of said gear-shaped members adapted to confine the atmospheric air driven by the said teeth, and means associated with each of said housings adapted to conduct said driven air and impinge it upon said glass stream prior to its entry between said intermeshed members for chilling'said glass stream.

3. Apparatus for producing crimped fibrous glass which comprises means for flowing a stream of molten glass, intermeshing driven gear-shaped members having radiallyextending teeth around the periphery thereof between which, said glass stream passes and by which it is attenuated and crimped,-means for applying a lubricant to said glass stream prior to its crimping between said intermeshed members, a housing individual to and around each of saidgear-shapecl members adapted to conduct the atmospheric air driven by the said teeth, and means'associated with each of said housings adaptedto'conduct said driven air and impinge it upon said glass stream prior to its entry between said intermeshed members for chilling said glass stream.

4. "Apparatus for producing crimped fibrous glass which comprises means for flowing a stream.

of molten glass, intermeshing crimping rolls each having spaced radially extending teeth around the periphery thereof between which said glass stream passes and by which it is attenuated and crimped, the spaces between said teeth being substantially greater than the size of said teeth, individual shafts upon which said crimping rolls are respectively rotativelymounted, synchronous reluctance motors individual to each of said shafts,

andhaving the rotors. thereof mounted on and, keyed respectively to said shafts, and a high frequency electrical energy source supplying energy simultaneously to each of said motors to drive the same at synchronous speeds.

5. Apparatus for producing crimped fibrous lass which comprises means for flowing streams of viscous glass, intermeshing gear-like rotors between which said streams pass to be attenuated and crimped, a pair of intermeshing driving gears, a gear train between each of said driving gears and one of said rotors to drive said rotors in synchronism, and an arm mounted for pivotal movement'about the axis of one of said driving gears and supporting one of said gear trains and rotors, whereby the rotor mounted thereon may be moved ,into and out of meshing relation with the other members having radially extending teeth around the periphery thereof between which said glass stream passes and by which it is simultaneously attenuated and crimped, a housing individual to and around each of said gear-shaped members adapted to confine the atmospheric air driven by the said teeth, means for introducing lubricant in the form of vapor into said housing to-mingle with said driven air, and means associated with said housing to conduct said lubricant laden driven air and impinge it upon said glass stream prior to its entry between said intermeshed members to lubricate said glass stream prior to its contact with said members.

7.Glass fiber attenuating and crimping apparatus comprising means for flowing a stream of viscous glass, spaced apart intermeshing gearlike members between which said stream passes and by which it is attenuated and crimped, bearings tor rotatably supporting said members, relatively movable toward and from each other to move said members into and out of meshing relation, a stop coacting with said hearings to limit relative movement thereof toward each other, and means for adjusting said stop for adjustably varying the degree of intermeshing thereof.

GAMES SLAYTER. 

